Abstract
Problem statement: In a coating process, the master plate referenced brightness or color shade was critical to the exterior appearance on aluminum alloy wheels. The quality measures of interest are the metallic paint thickness values on four areas. Because of these lower quality levels, the manufacturer has spent more on the cost of restudy or scrap as well as the longer production time. Approach: An expert system revealed seven process variables affecting those quality characteristics. Taguchi signal to noise ratio or SN of paint thickness values on the outboard spoke area was determined as a process response whereas SN on the remaining areas of window outboard, window between spoke and inboard spoke became merely process constraints. A constrained response surface optimization method and a modified complex method were performed to move the current operating condition towards the optimum. Results: The new settings improved the paint thickness values in terms of both the average and the standard deviation on all critical areas except the window between spoke. Conclusion: As expected, the implementation brings the reduction of the metallic paint consumption and the mismatch level of color shade.
Highlights
The selections of aluminum alloy wheels are based on the performance, the feature and the appearance
All quality measures of interest on aluminum alloy wheels consist of the metallic paint thickness on four areas or zones of Z1-Z4 and the mismatch of color shade determined by the master plate referenced brightness
This study proposes the Modified Complex Method (MCM) to optimize the constrained signal to noise response surface for the Electrostatic Powder Coating Process (EPCP)
Summary
The selections of aluminum alloy wheels are based on the performance, the feature and the appearance. The first time quality level is low at 75% and this leads to the high production cost of restudy or scrap To decrease such problem, a system with electrostatic spraying guns is invested for a painting process and it is referred to as an Electrostatic Powder Coating Process (EPCP) (Fig.). Within safe limits, but optimal conditions are rarely Various Taguchi parameter designs and performance attained and increased international competition means measures were applied on many engineering problems that deviations from the optimum can have serious and brought proper levels of operating conditions and financial consequences. The best choices of Taguchi parameter design and two sequential procedures are applied to the electrostatic powder coating process, but the performance measure on both the sample mean and standard deviation in terms of the signal to noise ratio is used as a process response instead of the conventional yield.
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